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OM-2230T

2008-09

Processes
Stick (SMAW) Welding Air Plasma Cutting and Gouging Air Carbon Arc (CAC-A) Cutting and Gouging

Description

Arc Welding Power Source

SRH-444

OWNER'S MANUAL
File :Stick (SMAW)
Visit our website at

www.MillerWelds.com

From Miller to You


Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you dont have time to do it any other way. Thats why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldnt afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. Theyre just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owners Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. Weve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, theres a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. particular model are also provided.
Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business.

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 200504

TABLE OF CONTENTS
SECTION 1 - SAFETY PRECAUTIONS READ BEFORE USING............................................................................................................1 1-1.Symbol Usage...............................................................................................................................................................................1 1-2.Arc Welding Hazards....................................................................................................................................................................1 1-3.Additional Symbols For Installation, Operation, And Maintenance...............................................................................................3 1-4.California Proposition 65 Warnings...............................................................................................................................................4 1-5.Principal Safety Standards............................................................................................................................................................4 1-6.EMF Information............................................................................................................................................................................4 SECTION 2 - CONSIGNES DE SCURIT LIRE AVANT UTILISATION................................................................................................5 2-1.Symboles utiliss..........................................................................................................................................................................5 2-2.Dangers relatifs au soudage larc...............................................................................................................................................5 2-3.Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance...................................................7 2-4.Proposition californienne 65 Avertissements................................................................................................................................9 2-5.Principales normes de scurit.....................................................................................................................................................9 2-6.Information EMF............................................................................................................................................................................9 SECTION 3 - DEFINITIONS......................................................................................................................................................................10 3-1.Electric Shock And Airflow Label................................................................................................................................................10 3-2.Nameplate Safety Symbols.........................................................................................................................................................10 3-3.Symbols And Definitions.............................................................................................................................................................10 SECTION 4 - INSTALLATION....................................................................................................................................................................11 4-1.Serial Number And Rating Label Location..................................................................................................................................11 4-2.Specifications..............................................................................................................................................................................11 4-3.Duty Cycle And Overheating.......................................................................................................................................................11 4-4.Volt-Ampere Curves....................................................................................................................................................................12 4-5.Selecting A Location...................................................................................................................................................................12 4-6.Dimensions and Weight..............................................................................................................................................................13 4-7.Tipping........................................................................................................................................................................................14 4-8.Selecting And Preparing Weld Output Cables............................................................................................................................14 4-9.Selecting Weld Cable Sizes*.......................................................................................................................................................15 4-10.Connecting To Weld Output Terminals.....................................................................................................................................16 4-11.Weld Output Terminals.............................................................................................................................................................16 4-12.Remote Amperage Control Receptacle....................................................................................................................................17 4-13.Electrical Service Guide............................................................................................................................................................18 4-14.Connecting Input Power............................................................................................................................................................19 SECTION 5 - OPERATION........................................................................................................................................................................22 5-1.Controls.......................................................................................................................................................................................22 5-2.Remote Amperage Switch..........................................................................................................................................................23 SECTION 6 - MAINTENANCE...................................................................................................................................................................24 6-1.Routine Maintenance..................................................................................................................................................................24 6-2.Overload Protection....................................................................................................................................................................24 SECTION 7 - TROUBLESHOOTING.........................................................................................................................................................25 7-1. Troubleshooting.........................................................................................................................................................................25 SECTION 8 - ELECTRICAL DIAGRAM.....................................................................................................................................................26 SECTION 9 - PARTS LIST ........................................................................................................................................................................27

SECTION 1 - SAFETY PRECAUTIONS READ BEFORE USING


Protect yourself and others from injury - read and follow these precautions.

1-1.Symbol Usage
DANGER! - Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates special instructions.


This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

NOTICE - Indicates statements not related to personal injury.

1-2.Arc Welding Hazards


The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away.

Properly install and ground this equipment according to its Owner's Manual and national, state, and local codes. Always verify the supply ground - check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first - double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord for damage or bare wiring - replace cord immediately if damaged - bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal.

ELECTRIC SHOCK can kill.


Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

SIGNIFICANT DC VOLTAGE exists in inverter-type welding power sources after removal of input power.
Turn off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

Page 1

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed. Allow cooling period before working on gun or torch.

Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

FUMES AND GASES can be hazardous.


Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer's instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

FLYING METAL or DIRT can injure eyes.

Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

ARC RAYS can burn eyes and skin.


Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator.

MAGNETIC FIELDS can affect Implanted Medical Devices.

Wearers of Pacemakers and other Implanted Medical Devices should keep away.

WELDING can cause fire or explosion.


Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

NOISE can damage hearing.


Noise from some processes or equipment can damage hearing.

Wear approved ear protection if noise level is high.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

Page 2

CYLINDERS can explode if damaged.


Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinderexplosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P1 listed in Safety Standards.

Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder.

1-3.Additional Symbols For Installation, Operation, And Maintenance


FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

Do not install or place unit on, over, or near combustible surfaces.

Do not install unit near flammables. Do not overload building wiring - be sure power supply system is properly sized, rated, and protected to handle this unit.

Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place.

Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

READ INSTRUCTIONS.

Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

Read Owners Manual before using or servicing unit.

Use only genuine replacement parts from the manufacturer.

OVERUSE can cause OVERHEATING.

H.F. RADIATION can cause interference.

Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again.

Highfrequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

Do not block or filter airflow to unit.

Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep highfrequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

FLYING SPARKS can cause injury.

Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

Sparks can cause fireskeep flammables away.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handling boards or parts.

Use proper staticproof bags and boxes to store, move, or ship PC boards.

MOVING PARTS can cause injury.

Keep away from moving parts. Keep away from pinch points such as drive rolls.

WELDING WIRE can cause injury.


Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. Page 3

ARC WELDING can cause interference.

Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computerdriven equipment such as robots.

Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

1-4.California Proposition 65 Warnings


Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other repro ductive harm. Wash hands after handling. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproduc tive harm. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth de fects, and other reproductive harm.

1-5.Principal Safety Standards


Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1877413 5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 18774135184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 022699101 (phone: 6177703000, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 7037882700, website:www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060
Mississauga, Ontario, Canada L4W 5NS (phone: 8004636727 or in Toronto 4167474044, website: www.csainternational.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 8002 (phone: 2126424900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 022699101 (phone: 617 7703000, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 152507954 (phone: 18665121800) (there are 10 Regional Officesphone for Region 5, Chicago, is 312353 2220, website: www.osha.gov).

1-6.EMF Information
Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a humanhealth hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. som 2007-04

Page 4

SECTION 2 - CONSIGNES DE SCURIT LIRE AVANT UTILISATION


Se protger et protger les autres contre le risque de blessure ; lire et respecter ces consignes.

2-1.Symboles utiliss
DANGER ! - Indique une situation dangereuse qui, si elle nest pas vite, entranera la mort ou des blessures graves. Les ventuels risques sont reprsents par les symboles joints ou expliqus dans le texte. Indique une situation dangereuse qui, si elle nest pas vite, risque dentraner la mort ou des blessures graves. Les ventuels risques sont reprsents par les symbols joints ou expliqus dans le texte.

Fournit des instructions spciales.


Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger lis aux CHOCS LECTRIQUES, aux PICES EN MOUVEMENT et aux PICES CHAUDES. Reportezvous aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.

NOTICE - Signale des consignes non associes aux dommages corporels.

2-2.Dangers relatifs au soudage larc


Les symboles prsents ci-aprs sont utiliss tout au long du prsent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnes afin dviter tout danger. Les consignes de scurit prsentes ci-aprs ne font que rsumer les informations contenues dans les normes de scurit numres la section 1-7. Veuillez lire et respecter toutes ces normes de scurit. Seul un personnel qualifi est autoris installer, faire fonc tionner, entretenir et rparer cet appareil. Pendant le fonctionnement, maintenir distance toutes les personnes, notamment les enfants de l'appareil. couche ; ou sil y a un risque lev de contact invitable ou accidentel avec la pice souder ou le sol. Dans ces conditions, utiliser les quipements suivants, dans lordre indiqu : 1) un poste souder DC tension constante ( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste souder AC tension vide rduite. Dans la plupart des situations, lutilisation dun poste souder DC fil tension constante est recommande. En outre, ne pas travailler seul !

Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit). Installer et relier correctement cet appareil la terre conformment son manuel dutilisation et aux codes nationaux, provinciaux et municipaux. Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. En effectuant les raccordements dentre, fixer dabord le conducteur de mise la terre appropri et vrifier nouveau les connexions. Les cbles doivent tre exempts dhumidit, dhuile et de graisse; protgez-les contre les tincelles et les pices mtalliques chaudes. Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud (remplacer le cordon immdiatement sil est endommag). Un cble dnud peut entraner la mort. L'quipement doit tre hors tension lorsqu'il n'est pas utilis. Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct. Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode provenant dune autre machine. Ne pas toucher aux porte-lectrodes relis deux postes de soudage en mme temps car une tension vide double sera prsente. Nutiliser quun matriel en bon tat. Rparer ou remplacer surle-champ les pices endommages. Entretenir lappareil conformment ce manuel. Page 5

UNE DCHARGE LECTRIQUE peut entraner la mort.


Un simple contact avec des pices lectriques peut provoquer une lectrocution ou des blessures graves. Llectrode et le circuit de soudage sont sous tension ds que lappareil est sur ON. Le circuit dentre et les circuits internes de lappareil sont galement sous tension ce moment-l. En soudage semiautomatique ou automatique, le fil, le dvidoir, le logement des galets dentranement et les pices mtalliques en contact avec le fil de soudage sont sous tension. Des matriels mal installs ou mal mis la terre prsentent un danger.

Ne pas toucher aux pices lectriques sous tension. Porter des gants isolants et des vtements de protection secs et sans trous. Sisoler de la pice couper et du sol en utilisant des housses ou des tapis assez grands afin d'viter tout contact physique avec la pice couper ou le sol. Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber. Se servir dune source lectrique courant lectrique UNIQUEMENT si le procd de soudage le demande. Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est quip. Dautres consignes de scurit sont ncessaires dans les conditions suivantes : risques lectriques dans un environnement humide ou si lon porte des vtements mouills ; sur des structures mtalliques telles que sols, grilles ou chafaudages ; en position coince comme assise, genoux ou

Porter un harnais de scurit si lon doit travailler au-dessus du sol. Sassurer que tous les panneaux et couvercles sont correctement en place. Fixer le cble de retour de faon obtenir un bon contact mtalmtal avec la pice souder ou la table de travail, le plus prs possible de la soudure. Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique. Ne pas raccorder plus dune lectrode ou plus dun cble de masse une mme borne de sortie de soudage.

LES RAYONS D'ARC peuvent entraner des brlures aux yeux et la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brlures dans les yeux et sur la peau. Des tincelles sont projetes pendant le soudage.

Porter un casque de soudage approuv muni de verres filtrants appropri pour protger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit). Porter des protections approuves pour les oreilles si le niveau sonore est trop lev. Avoir recours des crans protecteurs ou des rideaux pour protger les autres contre les rayonnements les blouissements et les tincelles ; prvenir les personnes prsentes sur les lieux quelles ne doivent pas regarder l'arc. Porter des vtements confectionns avec des matires rsistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

Il reste une TENSION DC NON NGLIGEABLE dans les sources de soudage onduleur quand on a coup lalimentation.
Arrter londuleur, dbrancher le courant lectrique et dcharger les condensateurs dalimentation selon les instructions indiques dans la partie entretien avant de toucher les pices.

DES PICES CHAUDES peuvent provoquer des brlures graves.

LE SOUDAGE peut provoquer un incendie ou une explosion.


Le soudage effectu sur des conteneurs ferms tels que des rservoirs, tambours ou des conduites peut provoquer leur clatement. Des tincelles peuvent tre projetes de larc de soudure. La projection dtincelles, des pices chaudes et des quipements chauds peuvent provoquer des incendies et des brlures. Le contact accidentel de llectrode avec des objets mtalliques peut provoquer des tincelles, une explosion, une surchauffe ou un incendie. Avant de commencer le soudage, vrifier et sassurer que lendroit ne prsente pas de danger.

Ne pas toucher des parties chaudes mains nues.

Prvoir une priode de refroidissement avant dutiliser le pistolet ou la torche. Ne pas toucher aux pices chaudes, utiliser les outils recommands et porter des gants de soudage et des vtements pais pour viter les brlures.

LES FUMES ET LES GAZ peuvent tre dangereux.


Le soudage gnre des fumes et des gaz. Leur inhalation peut tre dangereuse pour la sant.

Dplacer toutes les substances inflammables une distance de 10,7 m de larc de soudage. En cas dimpossibilit, les recouvrir soigneusement avec des protections homologues. Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables. Se protger, ainsi que toute autre personne travaillant sur les lieux, contre les tincelles et le mtal chaud. Des tincelles et des matriaux chauds du soudage peuvent facilement passer dans dautres zones en traversant de petites fissures et des ouvertures. Afin d'liminer tout risque de feu, tre vigilant et garder toujours un extincteur la porte de main. Le soudage effectu sur un plafond, plancher, paroi ou sparation peut dclencher un incendie de lautre ct. Ne pas effectuer le soudage sur des conteneurs ferms tels que des rservoirs, tambours, ou conduites, moins quils naient t prpars correctement conformment AWS F4.1 (voir les normes de scurit). Ne soudez pas si lair ambiant est charg de particules, gaz, ou vapeurs inflammables (vapeur dessence, par exemple). Brancher le cble de masse sur la pice le plus prs possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques dlectrocution, dtincelles et dincendie. Ne pas utiliser le poste de soudage pour dgeler des conduites geles. En cas de non-utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact. Porter des vtements de protection exempts d'huile tels que des gants en cuir, une veste rsistante, des pantalons sans revers, des bottes et un casque.

Ne pas mettre sa tte au-dessus des vapeurs. Ne pas respirer ces vapeurs. lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau de larc pour lvacuation des fumes et des gaz de soudage. Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approuv. Lire et comprendre les spcifications de scurit des matriaux (MSDS) et les instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs. Travailler dans un espace ferm seulement sil est bien ventil ou en portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage peuvent dplacer lair et abaisser le niveau doxygne provoquant des blessures ou des accidents mortels. Sassurer que lair de respiration ne prsente aucun danger. Ne pas souder dans des endroits situs proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de larc peuvent ragir en prsence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des mtaux munis dun revtement, tels que lacier galvanis, plaqu en plomb ou au cadmium moins que le revtement nait t enlev dans la zone de soudure, que lendroit soit bien ventil et en portant un respirateur alimentation dair. Les revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques en cas de soudage.

Page 6

Avant de souder, retirer toute substance combustible de ses poches telles quun allumeur au butane ou des allumettes. Une fois le travail achev, assurez-vous quil ne reste aucune trace dtincelles incandescentes ni de flammes. Utiliser exclusivement des fusibles ou coupe-circuits appropris. Ne pas augmenter leur puissance; ne pas les ponter. Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B pour travaux de soudage et prvoir un dtecteur dincendie et un extincteur proximit.

LES BOUTEILLES peuvent exploser si elles sont endommages.


Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommage, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procd de soudage, les manipuler avec prcaution.

DES PICES DE MTAL ou DES SALETS peuvent provoquer des blessures aux yeux.

Protger les bouteilles de gaz comprim dune chaleur excessive, des chocs mcaniques, des dommages physiques, du laitier, des flammes ouvertes, des tincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empcher de tomber ou de se renverser. Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques. Ne jamais placer une torche de soudage sur une bouteille gaz. Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurise car il existe un risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs, tuyaux et raccords convenables pour cette application spcifique ; les maintenir ainsi que les lments associs en bon tat. Dtourner votre visage du dtendeur-rgulateur lorsque vous ouvrez la soupape de la bouteille. Le couvercle du dtendeur doit toujours tre en place, sauf lorsque la bouteille est utilise ou qu'elle est relie pour usage ultrieur. Utiliser les quipements corrects, les bonnes procdures et suffisamment de personnes pour soulever et dplacer les bouteilles. Lire et suivre les instructions sur les bouteilles de gaz comprim, l'quipement connexe et le dpliant P-1 de la CGA (Compressed Gas Association) mentionn dans les principales normes de scurit.

Le soudage, lcaillement, le passage de la pice la brosse en fil de fer, et le meulage gnrent des tincelles et des particules mtalliques volantes. Pendant la priode de refroidissement des soudures, elles risquent de projeter du laitier. Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort.

Fermer lalimentation du gaz protecteur en cas de nonutilisation. Veiller toujours bien arer les espaces confins ou se servir dun respirateur dadduction dair homologu.

Les CHAMPS MAGNTIQUES peuvent affecter les implants mdicaux.

Les porteurs de stimulateurs cardiaques et autres implants mdicaux doivent rester distance.

Les porteurs dimplants mdicaux doivent consulter leur mdecin et le fabricant du dispositif avant de sapprocher des oprations de soudage larc, de soudage par points, de gougeage, de coupage plasma ou de chauffage par induction.

LE BRUIT peut endommager l'oue.


Le bruit des processus et des quipements peut affecter loue.

Porter des protections approuves pour les oreilles si le niveau sonore est trop lev.

2-3.Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance


Risque DINCENDIE OU DEXPLOSION.

Utiliser un quipement de levage de capacit suffisante pour lever lappareil. En utilisant des fourches de levage pour dplacer l'unit, s'assurer que les fourches sont suffisamment longues pour dpasser du ct oppos de l'appareil.

Ne pas placer lappareil sur, au-dessus ou proximit de surfaces inflammables.

Ne pas installer l'appareil proximit de produits inflammables Ne pas surcharger linstallation lectrique et sassurer que lalimentation est correctement dimensionne et protge avant de mettre lappareil en service.

LEMPLOI EXCESSIF peut SURCHAUFFER LQUIPEMENT.

LA CHUTE DE LAPPAREIL peut blesser.

Prvoir une priode de refroidissement ; respecter le cycle opratoire nominal.

Utiliser l'anneau de levage uniquement pour soulever l'appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.

Rduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages dair du poste. Page 7

LES TINCELLES VOLANTES risquent de provoquer des blessures.

Nutiliser que les pices de rechange recommandes par le constructeur.

Porter un cran facial pour protger le visage et les yeux.

Affter llectrode au tungstne uniquement la meuleuse dote de protecteurs. Cette manuvre est excuter dans un endroit sr lorsque lon porte lquipement homologu de protection du visage, des mains et du corps. Les tincelles risquent de causer un incendie ; loigner toute substance inflammable.

LE RAYONNEMENT HAUTE FRQUENCE (HF) risque de provoquer des interfrences.

Le rayonnement haute frquence peut provoquer des interfrences avec les quipements de radionavigation et de communication, les services de scurit et les ordinateurs. Demander seulement des personnes qualifies familiarises avec des quipements lectroniques de faire fonctionner l'installation. L'utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interfrences rsultant de l'installation. Si le FCC signale des interfrences, arrter immdiatement l'appareil. Effectuer rgulirement le contrle et l'entretien de l'installation. Maintenir les portes et les panneaux des sources de haute frquence soigneusement ferms, maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour rduire les interfrences ventuelles.

LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

tablir la connexion avec la barrette de terre AVANT de manipuler des cartes ou des pices.

Utiliser des pochettes et des botes antistatiques pour stocker, dplacer ou expdier des cartes de circuits imprims.

DES ORGANES MOBILES peuvent provoquer des blessures.

Ne pas sapprocher des organes mobiles.

Ne pas sapprocher des points de coincement tels que des rouleaux de commande.

LE SOUDAGE LARC risque de provoquer des interfrences.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

Ne pas appuyer sur la gchette avant den avoir reu linstruction.

Lnergie lectromagntique risque de provoquer des interfrences pour lquipement lectronique sensible tel que les microprocesseurs, les ordinateurs et les quipements commands par ordinateur tels que les robots.

Ne pas diriger la torche vers soi, dautres personnes ou toute pice mcanique en engageant le fil de soudage.

Veiller ce que tout lquipement de la zone de soudage soit compatible lectromagntiquement. Pour rduire la possibilit dinterfrence, maintenir les cbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller souder une distance de 100 mtres de tout quipement lectronique sensible. Veiller ce que ce poste de soudage soit pos et mis la terre conformment ce mode demploi. En cas dinterfrences aprs avoir pris les mesures prcdentes, il incombe lutilisateur de prendre des mesures supplmentaires telles que le dplacement du poste, lutilisation de cbles blinds, lutilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

DES ORGANES MOBILES peuvent provoquer des blessures.

S'abstenir de toucher des organes mobiles tels que des ventilateurs.

Maintenir ferms et verrouills les portes, panneaux, recouvrements et dispositifs de protection. Seules des personnes qualifies sont autorises enlever les portes, panneaux, recouvrements ou dispositifs de protection pour lentretien. Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand lentretien est termin et avant de rebrancher lalimentation lectrique.

LIRE LES INSTRUCTIONS.

Lire le manuel dutilisation avant dutiliser ou dintervenir sur lappareil.

Page 8

2-4.Proposition californienne 65 Avertissements


Les quipements de soudage et de coupage produisent des fumes et des gaz qui contiennent des produits chimiques dont ltat de Californie reconnat qu'ils provoquent des mal formations congnitales et, dans certains cas, des cancers. (Code de sant et de scurit de Californie, chapitre 25249.5 et suivants) Les batteries, les bornes et autres accessoires contiennent du plomb et des composs base de plomb, produits chi miques dont ltat de Californie reconnat qu'ils provoquent des cancers et des malformations congnitales ou autres problmes de procration. Se laver les mains aprs manip ulation. Pour les moteurs essence : Les gaz dchappement des moteurs contiennent des pro duits chimiques dont ltat de Californie reconnat qu'ils pro voquent des cancers et des malformations congnitales ou autres problmes de procration. Pour les moteurs diesel : Les gaz dchappement des moteurs diesel et certains de leurs composants sont reconnus par ltat de Californie comme provoquant des cancers et des malformations con gnitales ou autres problmes de procration.

2-5.Principales normes de scurit


Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (tlphone : 1-877-413-5184, site Internet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (tlphone : 1-877-413-5184, site Internet : www.global.ihs.com). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org et www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (tlphone : 7037882700, website:www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 5060 Mississauga, Ontario, Canada L4W 5NS (tlphone :
800-463-6727 ou Toronto 416-747-4044, site Internet : www.csainternational.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002 (tlphone : 212-642-4900, site Internet : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (tlphone : 617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureaux rgionaux et le tlphone de la rgion 5, Chicago, est le 312-353-2220, site Internet : www.osha.gov).

2-6.Information EMF
Considrations sur le soudage et les effets de basse frquence et des champs magntiques et lectriques. Le courant de soudage, pendant son passage dans les cbles de soudage, causera des champs lectromagntiques. Il y a eu et il existe encore des problmes concernant ces champs. Cependant, aprs avoir examin plus de 500 tudes qui ont t faites pendant une priode de recherche de 17 ans, un comit spcial ruban bleu du National Research Council a conclu : Laccumulation de preuves, suivant le jugement du comit, na pas dmontr que lexposition aux champs magntiques et champs lectriques haute frquence reprsente un risque la sant humaine . Toutefois, des tudes sont toujours en cours et les preuves continuent tre examines. En attendant que les conclusions finales de la recherche soient tablies, il vous serait souhaitable de rduire votre exposition aux champs lectromagntiques pendant le soudage ou le coupage. Pour rduire les champs magntiques sur le poste de travail, appliquer les procdures suivantes : 1. Maintenir les cbles ensemble en les torsadant ou en les attachant avec du ruban adhsif ou avec une housse. 2. Disposer les cbles d'un ct et distance de l'oprateur. 3. Ne pas courber pas et ne pas entourer pas les cbles autour de votre corps. 4. Garder le poste de soudage et les cbles le plus loin possible de vous. 5. Connecter la pince sur la pice aussi prs que possible de la soudure. propos des implants mdicaux : Les porteurs dimplants mdicaux doivent consulter leur mdecin et le fabricant du dispositif avant de raliser ou de sapprocher des oprations de soudage larc, de soudage par points, de gougeage, de coupage plasma ou de chauffage par induction. En cas dautorisation du mdecin, il est conseill de respecter les procdures ci-dessus. som 2007-04

Page 9

SECTION 3 - DEFINITIONS
3-1.Electric Shock And Airflow Label
1
1 2 3

Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring and exposed weld terminals can kill. Close door before turning on unit.
1/96

2 3
S179563

179 563

3-2.Nameplate Safety Symbols


1
1 1

Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. Sparks from arcing electrode can cause explosion or fire disconnect cable for process not in use. Read Owner's Manual for connection procedures. Electric shock from wiring can kill. Disconnect input power before working on unit or making terminal strip connections.
Ref. 179 389

2 3

4
5 2 3 4 6

5 6

3-3.Symbols And Definitions

Amperes

Volts

Percent

Protective Earth (Ground)

Output

Input

Remote

Supplementary Protector

Off

On

Positive

Negative

Voltage Control/Panel

Page 10

SECTION 4 - INSTALLATION
4-1.Serial Number And Rating Label Location
The serial number and rating information is located the front panel. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2.Specifications
Model Rated Welding Output Amp Range DC Max OCV DC IP Rating Amperes Input at Rated Load Output, 60 Hz, Three-Phase 208 V 75 23M 89 5.8* *While Idling 230 V 80 5.3* 460 V 40 2.6* 575 V 32 2.1* 31.9 2.1* 19.6 0.8* kVA kW

400 Amp

400 A @ A (Low) 30 36 Volts - 280 DC, 60 Hz, B (High) 60% Duty 50 - 500 Cycle

4-3.Duty Cycle And Overheating


Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

NOTICE - Exceeding duty cycle can damage unit and void warranty.
1 2 Six Minutes Welding Four Minutes Resting

A/V
15

Minutes

OR Reduce Duty Cycle

144 523-B

Page 11

4-4.Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown.

144 521-A

4-5.Selecting A Location
1 2 Lifting Eye Lifting Forks

Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit.
1

Line Disconnect Device

Locate unit near correct input power supply.


OR 2

Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20.

18 in. (460 mm)

18 in. (460 mm)


Ref. 800 402-A / Ref. 139 445-E

Page 12

4-6.Dimensions and Weight

A C

G F E

Inches A B C D E F G H J 30-1/4 22-1/2 35-3/4 20 1-1/4 1-1/2 4-1/2 29-3/4 in. Dia. (6 Holes) Weight 755 lb (342 (kg)

Millimeters 768 571 908 508 32 38 114 755 13 mm Dia. (6 Holes)

ABC Dimensions / 800 039

Page 13

4-7.Tipping
Do not move or operate unit where it could tip.

Tipping 2

4-8.Selecting And Preparing Weld Output Cables


1 Weld Output Cable Determine total cable length in weld circuit and maximum welding amperes. See Section 4-8 to select proper cable size. Use shortest cables possible. Do not use damaged cables.
2 2 1 3

Terminal Lug

Use lugs of proper amperage capacity and hole size for connecting to work clamp, electrode holder, and weld output terminals.
5 4

10 ft (3 m)

Insulated Electrode Holder

Install according to manufacturer's instructions. 4 Work Clamp

10 ft (3 m)

Install onto work cable. 5 Example: Total Cable Length In Weld Circuit = 20 ft. (6 m)

Tools Needed:

Weld Cable1

Page 14

4-9.Selecting Weld Cable Sizes*

Turn off power before connecting to weld output terminals. Do not use worn, damaged, undersized, or poorly spliced cables.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** Welding Amperes 100 150 200 250 300 350 400 500 600 100 ft (30 m) or Less 10 - 60% Duty Cycle 4 (20) 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 2/0 (70) 3/0 (95) 60 - 100% Duty Cycle 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 2/0 (70) 3/0 (95) 4/0 (120) 4 (20) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 3 (30) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m)

10 - 100% Duty Cycle 2 (35) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 1 (50) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 1/0 (60) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120)

* This chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable. ** Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use. *** For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Page 15

4-10.Connecting To Weld Output Terminals


Turn off power before connecting to weld output terminals. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.

1 6 3

Do not place anything between weld cable terminal and copper


bar. Make sure the surface of the weld cable terminal and copper bar are clean.
1 2

Correct Weld Cable Installation Incorrect Weld Cable Installation Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminals is tight against copper bar.

4 5

3 4 5 6

Tools Needed: 3/4 in. (19 mm)


803 778-B

4-11.Weld Output Terminals


Turn off power before connecting to weld output terminals. Use only one negative weld output terminal at a time. 1 2 3 Positive (+) Weld Output Terminal A Negative (-) Weld Output Terminal (Low Range) B Negative (-) Weld Output Terminal (High Range)

For DC Electrode Positive (DCEP), connect work cable to negative (-) terminal that supplies desired amperage range. Connect electrode holder cable to positive (+) terminal. For DC Electrode Negative (DCEN) reverse cable connections. Tools Needed: 3/4 in. (19 mm)
Ref. 802 927

Page 16

4-12.Remote Amperage Control Receptacle


1 2
2

Remote Amperage Control Receptacle RC1 Keyway

To connect remote amperage control to receptacle, insert plug and turn clockwise until tight.
1

Ref. 802 927

Page 17

4-13.Electrical Service Guide


Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes1 Time Delay Fuse2 Normal Operating Fuse3 Min Input Conductor Size In AWG4 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG4 110 125 4 171 (52) 6 100 125 6 142 (43) 6 50 60 8 375 (114) 10 40 50 10 395 (120) 10 208 89 230 80 460 40 575 32

Reference: 2005 National Electrical Code (NEC) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 "Time-Delay" fuses are UL class "RK5". 3 "Normal Operating" (general purpose - no intentional delay) fuses are UL class "K5" (up to and including 60 amp), and UL class "H" ( 65 amp and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

Page 18

4-14.Connecting Input Power


A.Placing Jumper Links

208 VOLTS
L1 L2 L3

230 VOLTS
L1 L2 L3

460 VOLTS
L1 L2 L3 S011 406B

230 VOLTS
L 1 L 2 L 3

460 VOLTS
L 1 L 2 L 3

575 VOLTS
L 1 L 2 L 3 S-094 120-B

Disconnect and lockout/tagout input power before installing or moving jumper links. Jumper links allow operation on different input voltages and are factory set for the highest input voltage. Check input voltage available at site. Open rear panel access door to check jumper links.

Input Voltage Label - Only One Is On Unit

Tighten jumperlinkNnuts to 25 in. lb 5 in. lb (2.8 N m 6 m)


. .

Look at jumper links and compare link position with unit label. 2 Input Voltage Jumper Links

Close and secure door or go to Section B. Tools Needed: 3/8 in.

Move links to match input voltage. For example, use 230 volts position when 230 volts input power is available.

Ref. 800 042

Page 19

B.Connecting 3-Phase Input Power For Models With Customer-Supplied Cord

= GND/PE Earth Ground 8

10

9 2 4 6

= GND/PE Earth Ground

L1 (U)

L2 (V)

L3 (W)

800 103-C / Ref. 801 116-A

Page 20

Installation must meet all National and Local Codes - have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Make input power connections to the welding power source first. Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.

Welding Power Source Input Power Connections 2 Strain Relief

Disconnect Device Input Power Connections 7 8 Disconnect Device (switch shown in OFF position) Disconnect Device (Supply) Grounding Terminal

Route conductors (cord) through strain relief and tighten screws. 3 4 Machine Grounding Terminal Green Or Green/Yellow Grounding Conductor

Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. 9 Disconnect Device Line Terminals

Tighten terminal nuts to 65 in. lb. 5 in. lb.

Connect green or green/yellow grounding conductor to welding power source grounding terminal first. 5 6 Welding Power Source Line Terminals Input Conductors L1 (U), L2 (V) And L3 (W)

Connect input conductors L1 (U), L2 (V) And L3 (W) to disconnect device line terminals. 10 Overcurrent Protection

See rating label on unit and check input voltage available at site. Input Power Conductors (Customer Supplied Cord)

Select size and length of conductors using Section 4-13. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.

Connect input conductors L1 (U), L2 (V) and L3 (W) to welding power source line terminals. Close and secure access door on welding power source.

Select type and size of overcurrent protection using Section 4-13 (fused disconnect switch shown). Close and secure door on line disconnect device. Remove lockout/tagout device, and place switch in the On position. Tools Needed: 3/8, 716, 1/2 in.

Page 21

SECTION 5 - OPERATION
5-1.Controls

Power Switch

Use switch to turn unit On and Off. 2 Amperage Adjustment Control

This amperage adjustment scale If applies to the SMAW process only.

4 5

Supplementary Protector (Section 6-2) Remote Amperage Switch (Section 5-2)

Use control to adjust amperage within range for Negative Weld Output terminal (see Section 4-11). Use A (inner) scale for low amperage range and B (outer) scale for high amperage range.

using this machine for the GTAW process, the scale does not apply. The actual output current while using the GTAW process is higher than the scale setting.
Remote Amperage Control Receptacle (Section 4-12)

122 035-B

Page 22

5-2.Remote Amperage Switch

5 6

Max (100 A DC)

Min (30 A DC)

NOTICE - Arcing can damage switch. Do not change Remote Amperage switch position while power is on. Arcing inside switch can damage contacts, causing switch to fail.
1 Remote Amperage Switch

For remote control, place switch in the Remote position and connect remote amperage control to remote amperage control receptacle (see Section 5-1). See example. 2 3 4 Example: Combination Remote Amperage Control Set Remote Amperage Switch Select Amperage Range

5 6

Select Maximum Amperage Adjust Remote Amperage Control

In example: Range Selected = 30 to 280 A DC Maximum Amperage Selected = 100 A DC Min = 30 A DC Max = 100 A DC
Ref. 122 035-B

Use switch to select way of controlling amperage adjustment. For front panel control, place switch in the Panel position.

Page 23

SECTION 6 - MAINTENANCE
6-1.Routine Maintenance

Disconnect Power before maintaining.

= Check

= Change

= Clean

= Replace

Reference

Every 3 Months

Unreadable Labels

Weld Cables

Weld Terminals

Every 6 Months

OR

Inside Unit

Sealed Bearings - No Oil Needed

6-2.Overload Protection
1 Supplementary Protector CB1 CB1 protects the welding power source control circuit from overload. If CB1 opens, weld output drops to the minimum of the range selected. Press button to reset protector.

Ref. 802 927

Page 24

SECTION 7 - TROUBLESHOOTING
7-1. Troubleshooting

Trouble

Remedy Place line disconnect switch in On position (see Section 4-14) Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-13). Check for proper input power connections (see Section 4-14). Check for proper jumper link position (see Section 4-14A). Clean and tighten all weld connections. Check for proper line voltage. Check for open line fuse(s), and replace if necessary. Check and replace circuit breakers (see Section 4-13B). Clean and tighten all weld connections (see Section 4-10). Place Remote Amperage switch in correct position (see Section 5-2). Select correct size weld cables (see Section 4-9).

No weld output; unit completely inoperative.

No weld output.

Unit provides only low or minimum weld output.

Low weld amperage; Amperage adjustment does not control amperage. Maximum weld output only. Erratic or improper weld output.

Reset supplementary protector CB1 (see Section 6-2). Have Factory Authorized Service Agent check Amperage Adjustment control. Check for proper input power connections (see Section 4-14. Clean and tighten all weld connections. Use proper size and type electrodes. Check for proper input power connections (see Section 4-14). Check for proper jumper link position (see Section 4-14A). Remove anything blocking fan movement. Check fan motor, and replace if necessary. The amperage adjustment scale applies to the Stick process only. The scale does not apply while using the TIG process. Actual output current is higher while using the TIG process.

Excessive line current or line fuse(s) open repeatedly. Fan not operating and/or unit is overheating. When TIG welding, output current does not match the Amperage Adjustment control setting.

Page 25

SECTION 8 - ELECTRICAL DIAGRAM

For primary circuit diagram portion, refer to circuit diagram located inside wrapper of welding power source.

Figure 8-1.Circuit Diagram


143 314-E

Page 26

SECTION 9 - PARTS LIST

is common Hardwareunless listed.and not available

11

10

12

13

15

Figure 9-1.Main Assembly

14

OM-2230T Page 27

Item No. 1 2 3 4 5

Dia. Mkgs. ................ ................ ........SR1 ........SR2 ........R2

Part No. ........ 006016 ........ 006890 ........ 204171 ........ 035704 ........ 071054

Description Figure 8-1. Main Assembly

Quantity ........ ........ ........ ........ ........ 2 1 1 1 1

........ Panel, Side ........ Cover, Top ........ Rectifier, Si Diode (400 Amp Model)(Eff W/Lb157023) ........ Rectifier, Integ 40 A 800 V ........ Resistor, Ww Adj 50W 2 Ohm (300 And 400 Amp 60 Hz Models) 6 ................ ........ 605741 ........ Clip, Mtg Resistor .312 Id Core (300 And 400 Amp 60 Hz Models) 7 ........MA1,T1 ........ 093929 ........ Xfmr & L,Pwr Main & Mag 208/230/460(400 Amp 60 Hz Model) (Includes) 8 ........Z ........ 036127 ........ Stabilizer 7 ........MA1,T1 ........ 093930 ........ Xfmr & L,Pwr Main & Mag 230/460/575 (400 Amp 60 Hz Model)(Includes) 8 ........Z ........ 036127 ........ Stabilizer 9 ................ ........ 026627 ........ Gasket, Lifting Eye 10 ................ ........ +010494........ Busing, Snap-In Nyl 1.375 Id X 1.750 Mtg Hole 11 ................ ........ Fig 8-3 ........ Panel, Rear W/Components 12 ........TE1 ........ 038138 ........ Terminal, Pri Term Assy, Pri 3Ph 3V (Includes) ........................ ........ 038618 ........ Jumper, Link 13 ................ ........ 211200 ........ Base 14 ................ ........ Fig 8-2 ........ Panel, Front W/Components 15 ................ ........ 217136 ........ Label, Warning Electric Shock (60 Hz)
+ One bushing (center) is included with the amplifier, transformer, stabilizer assembly.

........ 2 ........ 1 ........ 1 ........ 1 ........ ........ ........ ........ ........ ........ ........ ........ ........ 1 1 2 1 1 6 1 1 2

To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2230T Page 28

is common Hardwareunless listed.and not available


3 1 2 4 5 6

11 7

15

9 16 13 10 14

11

Figure 9-2.Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Figure 8-2 Panel, Front w/Components (Figure 8-1, Item 14) ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ 1 1 1 1 1 1 1 1 2 1 1 3 3 3 3 1 Quantity

1 ................ ........ +202923........ Panel, Front (Eff W/Lb157023) 2 ........CB1 ........ 083432 ........ Supplementary Protector, Man Rest 10A, 250 V Dc 3 ........RC1 ........ 039607 ........ Receptacle, Twlk 3P3w 20A, 250V ........................ ........ 605797 ........ Plug, Twlk 3P3w 20A 125V Arrow Hart 6312 4 ........S2 ........ 011609 ........ Switch, Tgl Spst 15A 125 V Ac 5 ........R1 ........ 222736 ........ Rheostat, Ww 150W 15 Ohm 6 ........S1 ........ 045835 ........ Switch, Tgl 3Pst 60 A 600 V Ac Screw Term 7 ................ ........ 181245 ........ Terminal, Pwr Output Red 8 ................ ........ 181246 ........ Terminal Pwr Output Black 9 ................ ........ ........ Nameplate, (Order By Model And Serial Number) 10 ................ ........ 097926 ........ Knob, Pointer 11 ................ ........ 186621 ........ Boot, Generic Output Stud 13 ................ ........ 181169 ........ Spacer, Output Stud (Eff W/Lb157023) 14 ................ ........ 180735 ........ Wsher, Negative Output Stud (Eff W/Lb157023) 15 ................ ........ 228672 ........ Label, Weld Cable Lug 16 ................ ........ 227980 ........ Label, Output Terminal Connection
+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2230T Page 29

is common Hardwareunless listed.and not available


5 4 6 7 3 2

Figure 9-3.Panel, Rear w/Components Item No. 1 2 3 4 5 6 7 8 Dia. Mkgs. Part No. Description Figure 8-3. Panel, Rear w/Components ........FM ........ 237398 ........ Motor, 1/12 Hp 230V 1550 Rpm 50/60 Hz ................ ........ 124275 ........ Chamber, Plenum 14 In. ................ ........ 180165 ........ Blade, Fan 14 In. 3Wg 28 Deg .375 Bore Ccw ................ ........ 226619 ........ Panel, Rear ................ ........ 168343 ........ Hinge, Cont Polyolefin Copolymer 2.000 L W/.125H ................ ........ +222621........ Panel Layout, Door Access ................ ........ 217733 ........ Label, Warning Electric Shock Input/Power (En/Fr) (60 Hz Models) ................ ........ 010467 ........ Conn, Clamp Cable 1.250 ........ ........ ........ ........ ........ ........ ........ 1 1 1 1 2 1 1 Quantity

........ 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2230T Page 30

Effective January 1, 2008 (Equipment with a serial number preface of LJ or newer)


Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.


Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls its original retail purchaser that new Miller equipment sold after * APT & SAF Model Plasma Cutting Torches the effective date of this limited warranty is free of defects in * Remote Controls material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Accessory (Kits) WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor) WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns Within the warranty periods listed below, Miller will repair or * Canvas Covers replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Millers True Blue Limited Warranty shall not apply to:

1.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.

Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.) Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

2. 3.

1.

2.

5 Years Parts 3 Years Labor * Original main power rectifiers only to include SCRs, diodes, and discrete rectifier modules 3 Years Parts and Labor * Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Inverter Power Sources (Unless Otherwise Stated) * Water Coolant Systems (Integrated) * Intellitig * Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year Parts and Labor Unless Specified * Motor Driven Guns (w/exception of Spoolmate Spoolguns) * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources, Coolers, and Electronic Controls/Recorders * Water Coolant Systems (Non-Integrated) * Flowgauge and Flowmeter Regulators (No Labor) * HF Units * Grids * Spot Welders * Load Banks * Arc Stud Power Sources & Arc Stud Guns * Racks * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF Models) * Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.) * Bernard-Branded Mig Guns (No Labor) * Weldcraft-Branded TIG Torches (No Labor) * Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts * MIG Guns and Subarc (SAW) Guns

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

3.

4. 5.

miller_warr 2008-01

Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.


Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks
To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.


An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International HeadquartersUSA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066
www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.


For assistance in filing or settling claims, contact your distributor and/or equipment manufacturers Transportation Department.

PRINTED IN USA

2008 Miller Electric Mfg. Co. 200801

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